Mattress system

ABSTRACT

Disclosed is a mattress including a plurality of springs arranged in rows to provide an innerspring, and at least one polymer fiber rail including polymer fibers interlinked with one another. The at least one polymer fiber rail has a face adjoining one of the rows of springs. The at least one polymer fiber rail can be tuned to provide desired characteristics, and, together with the springs, the rail provides a comprehensive mattress system.

RELATED APPLICATIONS

This disclosure claims the benefit of U.S. Provisional Application No. 61/491,438, filed 31 May 2011.

BACKGROUND OF THE INVENTION

Most sitting and sleeping surfaces today have a combination of coil springs and foam. Manufacturers attempt to tune the feel of the spring/foam combination to achieve durability and comfort. Foam chemistries have been manipulated to create various foam cores, of ranging quality and price. Further, foam has been used on the outside of a spring core assembly, or innerspring, as topper layers and as rails, or skirts.

SUMMARY OF THE INVENTION

Disclosed is a mattress including a plurality of springs arranged in rows to provide an innerspring. The mattress further includes at least one polymer fiber rail including polymer fibers interlinked with one another. The at least one polymer fiber rail has a face adjoining one of the rows of springs.

The at least one polymer fiber rail can be tuned to provide desired characteristics, and, together with the springs, the rail provides a comprehensive mattress system.

These and other features of the present disclosure can be best understood from the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings can be briefly described as follows:

FIG. 1A is a schematic view of the innerspring of this disclosure.

FIG. 1B is a side-view of the innerspring of FIG. 1A.

FIG. 2 is a perspective view of an example external rail.

FIG. 3A is a perspective view of an example rail.

FIG. 3B illustrates the engagement between the rail of FIG. 3A and a coil spring.

FIGS. 4A-4B are perspective views of example rails.

FIG. 5A schematically illustrates an example mattress.

FIG. 5B is a broken-away view of an example mattress.

DETAILED DESCRIPTION

Disclosed is a mattress system including a polymer fiber structure that is introduced into the spring core assembly, or innerspring, during the manufacturing process. The polymer fiber structure adjusts the tuning characteristics of the mattress to provide a desired motion transfer, vibration, and damping. The polymer fiber structures can further be localized to provide desired zones within the sleeping or seating surface for increased support, such as lumbar support. In this disclosure, the terms “tuning block,” “batt,” and “polymer fiber structure” are used interchangeably.

In one example, the polymer fiber structure is an engineered polyester fiber material. Other types of fibers may include polypropylene, nylon, elastomers, copolymers and its derivatives, including monofilament or bicomponent filaments having different melting points. An example polymer fiber structure according to this disclosure is wholly polyester structure, core polyester fibers that are sheathed in a polyester elastomer binder.

Engineered fibers can be solid or hollow and have cross-sections that are circular or triangular. Another type of polyester fiber has a tanged, spring-like structure. During manufacturing the polymer fiber structure is heated to interlink the fibers to one another to provide a more resilient structure. Fibers may be randomly oriented or directionally oriented, depending on desired characteristics. Such processes are discussed in U.S. application Ser. No. 13/157,540, the entirety of which is herein incorporated by reference.

The fibers and their characteristics are selected to provide desired tuning characteristics. One measurement of “feel” for a cushion is the indentation load deflection, or ILD As used herein, ILD is the amount of force required to compress a 15″×15″ batt of material having an original (or “relaxed”) height of 4″ to a fraction of its original height (or thickness). ILD is not limited to any particular type of material, and is a useful test for determining the “feel” of any batt of material, including composite batts, and even mattresses.

In one example, the disclosed polymer fiber structure exhibits an ILD of 88.56 lbs. when compressed to 3″ (e.g., the original height reduced by 25%) and an ILD of 92.70 lbs. when compressed to 1.4″ (e.g., the original height reduced by 65%). Accordingly, the disclosed polymer fiber structure provides a plush feel upon initial compression (e.g., when compressed to 3″) and firm support with increased compression (e.g., when compressed to 1.4″). This is contrary to foam, a block of which is not tunable, as polymer fiber structures are, and multiple layers of different foam densities are required to achieve similar results to the polymer fiber structures of this disclosure. For example, a certain block of foam exhibited an ILD of 90.56 when compressed to 25% of its original height, and an ILD of 87.23 when compressed to 65% of its original height.

Customers are known to require an initially plush feel and firm support with increased force in cushions, and particularly mattresses. Typically, expensive innersprings (either with expensive springs alone, or expensive springs in combination with expensive foam) were required to provide this level of performance. Using this disclosure, however, internal and external rails made of a polymer fiber blend can be combined with typical, relatively cheap, innersprings to provide the feel and support of a mattress that would typically have been much more expensive. Not only that, but unlike the foam typically used in a mattress construction, the disclosed polymer fiber structure is fully recyclable, inexpensive, fire resistant, sterile and easily manufactured.

FIGS. 1A and 1B schematically illustrate an example innerspring 10 according to this disclosure. The disclosed innerspring 10 includes a plurality of coil springs 12 arranged in rows to provide the innerspring with a length L, a width W and a height H. Between upper and lower points of the coil springs 12 are a plurality of wire springs 14 connecting the coil springs 12 to one another. In one example, the springs 12, 14 are steel springs.

In the example, a plurality of polymer fiber structures provide external rails 16 about a perimeter 18 of the innerspring. The external rails 16 are provided with engagement features (e.g., see FIGS. 2-4B) to engage the springs 12 at the perimeter 18 of the innerspring 10.

Between adjacent rows of springs 12, additional polymer fiber structures provide internal rails 20. As illustrated, the internal rails 20 extend along the width W of the innerspring 10. In other examples, the internal rails 20 can extend along the length L of the innerspring, or the internal rails 20 can be arranged to overlap one another, running along both the length L and the width W of the innerspring 10.

The internal rails 20 can be positioned in certain zones along the length and width of the innerspring 10 to provide increased support in desired areas. Further, and as noted below, the internal rails 20 can include engagement features to accommodate the coil springs 12 of the innerspring 10. This disclosure is not limited to simply providing increased local support, however, and instead provides, together with the springs of the innerspring 10, a comprehensive mattress system.

Turning to FIG. 2, an example external rail 16 is shown. In the example, an inner face 22 of the external rail 16 is provided with a plurality of the engagement features 24 configured to engage the coil springs 12 positioned at the perimeter 18 of the innerspring 10. In this example, the engagement features 24 are semi-circular cut-outs provided in the inner face 22. These cut-outs provide a desirable engagement between the external rail 16 and the coil springs 12, such that the external rail 16 is retained in position. The engagement features further allow the external rail 16 to effectively dampen the coil springs 12, and to provide a desired level of support at the outer perimeter of a mattress, for example. In this example, where the rail is an external rail 16, the face of the rail opposite the inner face 22 is generally smooth and planar.

With reference to FIGS. 3A-3B, another example rail is shown. As will be appreciated, this rail could be used as either an external rail 16 or an internal rail 20. Like the rail of FIG. 2, this rail also includes an inner face 30 provided with a plurality of engagement features. In this example the engagement features are angled slits 32 formed into the face 30. The angled slits 32 are angled such that they are generally parallel to an angle of the turns 34 in the coil spring 12, as illustrated in FIG. 3B. This angle in the slits 32 provides a desirable fit between the coil springs 12 and the internal rails 20, which leads to ease of assembly, and also allows the rail to effectively dampen the coil springs 12.

The engagement between the coil springs 12 and the rails, either internal and/or external, allows the innerspring 10 as a whole to exhibit properties similar to that of the polymer fiber structure making up the rails (e.g., increased plushness on initial compression, and increased firmness on further compression). Essentially, the engagement between the rails and the coil springs 12 dampens the normal spring rate of the coil springs 12.

Notably, while only one face 30 is shown in FIG. 3A, the opposite face 35 of the rail, especially in the case where the rail is an internal rail 20, could include engagement features to accommodate the springs 12 in an adjacent row.

FIGS. 4A-4B illustrates further examples of engagement features that could be incorporated into rails (either internal 20 or external 16). For example, FIG. 4A shows the face 30 of the internal rail 20 including a plurality of vertically spaced slots 38. The vertically spaced slots 36 are arranged to accommodate the turns of a coil spring 12 similar to the manner in which the angled slots 32 engage the coil spring 12, illustrated in FIG. 3B.

FIG. 4B illustrates another example rail (which again, could be either an internal rail 20 or an external rail 16) which includes a profile 38 formed in its face 30 including a plurality of protrusions 42 and indentations 44 which, similar to the FIG. 4A embodiment, are arranged to accommodate, and engage, the turns of the coil springs 12 from an adjacent row. Like the embodiment of FIGS. 3A-3B, the engagement features of FIGS. 4A-4B can also be provided on an opposing face to engage with springs 12 from an adjacent row, in the example where the rail is an internal rail 20. Further, the engagement features of FIGS. 2-4B can be provided using known manufacturing methods, including molding, or some type of post-processing.

An example innerspring 10 according to this disclosure includes external rails 16 around substantially the entire perimeter 18 thereof, and a desired number of internal rails 20. In one example, the polymer fiber structure making up the external railing 16 is tuned to be substantially stiffer than the polymer fiber structure making up the internal railing 20. This is due, in part, to the need for increased support when a user, or customer, sits on the edge of a mattress to put shoes on, etc. In these situations, the user applies a localized force that is typically not adequately supported with conventional spring, or spring-foam innersprings.

The external rails 16 do not need to be stiffer than the internal rails 20, however. The stiffness of the rails 16, 20 is selectively tunable depending on the intended application, customer requirements, etc.

The innerspring 10 including the polymer fiber structures, discussed above, can be incorporated into any type of mattress. One example of a mattress including the innerspring 10 is illustrated schematically in FIG. 5A. The mattress 50 includes a ticking fabric 52 intended to be an uppermost layer of the mattress 50, a polyester quilting layer 54 directly adjacent and below the ticking fabric 50, and a polyester topper pad 56 directly adjacent and below the quilting layer 54. The topper pad 56 may include two layers, one being a plusher layer, and the other being a firmer layer. Directly adjacent and below the topper pad 56 is a polyester insulator pad 58, which is adjacent the innerspring 10.

As noted above, the innerspring 10 is provided with a combination of springs 12, 14 and polymer fiber structures (e.g., the external and internal rails 16, 18). Below the innerspring 10 is another polyester insulator pad 60, below which is a polyester topper pad 62. Below the topper pad 62 is either a spunbonded cover 64, or optionally an additional layer of polyester quilting 66 and another layer of ticking fabric 68, depending on whether the mattress 50 is double-sided.

FIG. 5B illustrates one example mattress 50 including the innerspring 10 described above, and includes a ticking fabric 52, a polyester quilting layer 54, a plush, polyester topper layer 56 a, a firm, polyester topper layer 56 b, and a polyester insulator pad 58. The innerspring 10 is provided with a plurality of external rails 16 and a plurality of internal rails 20. Below the innerspring 10 is a base pad 70. Again, the examples of FIGS. 5A and 5B are non-limiting, and the innerspring 10 discussed herein can be incorporated into any number of mattresses.

Although the different examples have the specific components shown in the illustrations, embodiments of this invention are not limited to those particular combinations. It is possible to use some of the components or features from one of the examples in combination with features or components from another one of the examples.

One of ordinary skill in this art would understand that the above-described embodiments are exemplary and non-limiting. That is, modifications of this disclosure would come within the scope of the claims. Accordingly, the following claims should be studied to determine their true scope and content. 

1. A mattress comprising: a plurality of springs arranged in rows to provide an innerspring; and at least one polymer fiber rail including polymer fibers interlinked with one another, the at least one polymer fiber rail having a face adjoining one of the rows of springs.
 2. The mattress as recited in claim 1, wherein the at least one polymer fiber rail is an external rail, and wherein the face of the external rail adjoins springs from an outer perimeter of the innerspring.
 3. The mattress as recited in claim 2, wherein the external rail includes a smooth, planar face opposite the face adjoining the springs from the outer perimeter of the innerspring.
 4. The mattress as recited in claim 3, wherein the face includes engagement features engaged with at least some of the plurality of springs, and wherein the engagement features are clips.
 5. The mattress as recited in claim 1, wherein the at least one polymer fiber rail is an internal rail positioned between adjacent rows of springs, and wherein the internal rail includes two opposing faces, each of the two opposing faces including engagement features partially receiving springs from a respective one of the adjacent rows of springs.
 6. The mattress as recited in claim 1, wherein the at least one polymer fiber rail includes at least one internal rail and at least one external rail.
 7. The mattress as recited in claim 6, wherein the at least one polymer fiber rail includes four external rails provided about a perimeter of the innerspring.
 8. The mattress as recited in claim 6, wherein a plurality of internal rails are positioned adjacent one another to provide a zone of increased support.
 9. The mattress as recited in claim 8, wherein the plurality of internal rails provide a lumbar support zone.
 10. The mattress as recited in claim 1, wherein the face includes engagement features engaged with at least some of the plurality of springs, and wherein the engagement features are one of slits, vertically-spaced slots, and a spring-shaped cross sectional profile, the springs are at least partially received within the engagement features.
 11. The mattress as recited in claim 1, wherein the springs are steel coil springs providing a first spring rate, the internal rails provide a second spring rate, and the external rails provide a third spring rate, wherein the first, second and third spring rates are different from one another.
 12. The mattress as recited in claim 11, where the first, second, and third spring rates are tuned to meet customer requirements.
 13. The mattress as recited in claim 12, wherein the third spring rate is greater than the second spring rate.
 14. The mattress as recited in claim 1, wherein the polymer fiber rail is wholly polyester and includes polyester fibers interlinked by a polyester binder.
 15. The mattress as recited in claim 1, wherein a batt of material providing the polymer fiber rail exhibits an ILD of 88.56 lbs. reduced in height by 25%, and an ILD of 92.70 lbs. reduced in height by 65%.
 16. A mattress comprising: a quilting layer; at least one first topper pad adjacent the quilting layer; an insulator pad adjacent the first topper pad; a plurality of springs arranged in rows to provide an innerspring; and at least one polymer fiber rail including polymer fibers interlinked with one another, the at least one polymer fiber rail having a face adjoining one of the rows of springs, the face provided with a plurality of engagement features engaged with at least some of the plurality of springs.
 17. The mattress as recited in claim 16, wherein the at least one polymer fiber rail includes four external rails positioned about the outer perimeter of the innerspring, and at least one internal rail positioned between adjacent rows of springs.
 18. The mattress as recited in claim 16, wherein the at least one polymer fiber rail is an internal rail including two opposing faces, each of the two opposing faces including engagement features partially receiving springs from adjacent rows of springs.
 19. The mattress as recited in claim 16, wherein the at least one first topper pad includes a plush topper pad and a firm topper pad, the firm topper pad being firmer than the plush topper pad.
 20. A mattress comprising: a plurality of springs arranged in rows to provide an innerspring; and at least one polymer fiber rail including polymer fibers interlinked with one another, the at least one polymer fiber rail having a face adjoining one of the rows of springs, the face provided with a plurality of engagement features engaged with at least some of the plurality of springs. 